Repairing Aircraft Engine Forward Frame V-Blade Cracks
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Solution Overview
Problem
Aircraft engine components, such as forward frame v-blades, often develop cracks due to stress and misalignment, necessitating costly replacement rather than repair, which is undesirable due to scale, size, and complexity.
Innovation Solution
A repair device comprising a repair part and a splice plate with enhanced mechanical properties, including stiffening legs and fasteners, is used to repair damaged forward frame v-blades in place, maintaining structural integrity and preventing further cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the forward frame v-blade is replaced in its entirety, then the structural integrity and reliability are restored, but the cost, downtime, and complexity of maintenance increase significantly
Solution Approach 1:
The repair device segments the repair process into modular components: a repair part with stiffening legs, a separate splice plate, and an array of fasteners. This segmentation allows the repair to be performed on only the damaged section rather than replacing the entire v-blade, reducing maintenance complexity while restoring structural integrity
Solution Approach 2:
The splice plate acts as an intermediary element that couples the repair part to the forward frame v-blade. This intermediary component facilitates the connection between the existing structure and the repair reinforcement, enabling structural restoration without complete replacement
2Reliability
If the forward frame v-blade is replaced in its entirety, then the cracked component is eliminated, but the time and resources required for dismantling and reassembly increase
Solution Approach 1:
The repair part and splice plate are prepared as pre-fabricated components with predetermined geometries and attachment features. This preliminary preparation allows for rapid installation on the aircraft without requiring time-consuming fabrication or complex assembly procedures, reducing maintenance downtime while preventing crack propagation
Solution Approach 2:
By segmenting the repair into a localized repair part and splice plate assembly, the maintenance operation is confined to a specific section of the v-blade rather than requiring complete disassembly and replacement of the entire component, significantly reducing maintenance downtime
3Strength
If thicker stiffening legs are used in the repair part, then the bending stress resistance is improved, but the weight and volume of the repair device increase
Solution Approach 1:
The stiffening legs are designed with varying thicknesses tailored to the specific bending stress requirements at different locations of the v-blade. This local quality approach ensures adequate strength where needed while minimizing unnecessary material and weight in other areas, optimizing the strength-to-weight ratio of the repair device
Data Source
AI summary
A repair device and method for repairing a forward frame v-blade on an aircraft engine are described in which the repair device replaces a section of the forward frame v-blade. In one embodiment, the repair device includes a repair part and a splice plate, the combination of which is secured to the forward frame v-blade. The repair part includes a repair part web and a pair of stiffening legs with a leg thickness that is greater that the thickness of corresponding flanges on the forward frame v-blade. The splice plate is configured to accommodate for the increased thickness of the stiffening legs, providing by way of example a reduced thickness area compatible with the repair part. Fasteners such as rivets are used to couple the repair device to the splice plate, and to couple the splice plate to the forward frame v-blade.